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Cold Spray Coating Applications
Release time:
2020-08-28 16:19
Source:
Cold Spray Coating Applications
Due to the low particle temperature during cold spraying, the powder is less likely to undergo oxidative phase transformations. As a result, the microstructure of the coating formed is essentially unchanged compared to that of the powder before spraying. Consequently, a wide variety of powders can be used in cold spraying, including pure metal powders, alloy powders, and composite coatings, enabling the production of coatings with diverse properties. Currently, metals that can be deposited by this technique include Al, Zn, Cu, Ti, and Ag, as well as high-melting-point metals such as Mo and Ta. Alloy systems include NiCr and MCrAlY, while composite coatings encompass Zn-Al and Al-Al2O3. By avoiding the adverse effects of high temperatures on both the substrate and the coating, cold spraying technology has been widely adopted across various fields.
The design and research of cold spray technology are shifting toward industrial-scale applications. By leveraging cold spray technology, protective coatings—such as corrosion-resistant, high-temperature resistant, and wear-resistant coatings—can be prepared. Dong Caichang et al. used the cold spray process to deposit an aluminum coating on a Q235 steel substrate. The resulting aluminum coating exhibited an extremely dense surface with low porosity. Analysis of the AC impedance spectra and potentiodynamic polarization curves revealed that the corrosion products formed on the aluminum coating were densely packed at the coating surface, effectively hindering the diffusion of corrosive media and thus playing a highly effective role in reducing the corrosion rate of the coating. Neutral salt-spray tests demonstrated that the corrosion rate of the cold-sprayed coating could be rapidly reduced, providing effective cathodic protection for the steel substrate. Zhao Hui et al. employed the cold spray method to deposit an AZ20 zinc-aluminum alloy coating onto magnesium alloy AK63. The results showed that the coating exhibited a dense bond with the substrate, and its hardness was three times that of the substrate. After cold spraying, the magnesium alloy displayed significantly improved wear resistance compared to the base material.
The results of the salt-spray test indicate that the AZ20 cold-sprayed coating exhibits superior corrosion resistance compared to the magnesium alloy substrate, providing effective protection for the substrate. Functional coatings (such as amorphous coatings and composite coatings) can also be prepared using this method. Li Haixiang et al. used the cold-spray technique to deposit a Zn-50Al composite coating on a carbon steel substrate. The coating showed a low porosity of approximately 1.7%. Electrochemical tests revealed that the Zn-50Al coating had a low self-corrosion rate and a relatively stable corrosion potential, stabilizing around -0.990 V after 100 hours. This coating demonstrates excellent corrosion resistance, effectively protecting the steel substrate and significantly extending its service life.
Preparation of Nanocoatings. The low-temperature characteristic of cold-spray technology makes it particularly suitable for fabricating nanoscale structured coatings. Li Changjiu and colleagues successfully prepared nanoscale WC-Co coatings using the cold-spray method with nanostructured WC-12Co powder. The resulting coating exhibited a dense microstructure, and the nanostructures present in the thermal-spray powder were completely transferred to the coating during the cold-spray process. The average Vickers hardness of the coating was 1,869 HV0.3, significantly higher than that of thermally sprayed nanoscale WC-Co coatings. The study also showed that loose, porous powders are well-suited for preparing WC-Co coatings via cold spraying, as their loose and porous structure facilitates pseudo-plastic deformation of the powder particles. Upon examining the cross-sectional morphology of the WC-Co coating after heat treatment, no collapse was observed around the indentation, nor were any cracks detected. This indicates that the heat treatment process can markedly improve the bonding between coating particles and enhance the toughness of the coating.
In the aerospace field, this technology is also widely applied. Cold spray technology is used to prepare special protective coatings for aerospace engine components and to fabricate specialized functional coatings for aerospace weapons. Moreover, by means of spray forming, complex-structured and shaped aerospace parts can be directly manufactured.
For other applications, cold spraying is often the only feasible solution, especially as its use in non-traditional fields continues to grow. As environmental and health-and-safety regulations become increasingly stringent, interest in cold spraying has been rising as a potentially greener alternative.
With advances in technology, cold spray applications are expected to continue expanding into an increasing number of nontraditional fields, such as optoelectronics, wind energy, healthcare, and construction. In optoelectronic applications, cold spray can be used to manufacture complex conductive solar cells. In wind energy generation, cold spray can enhance the surface performance of components made from advanced polymer matrix composites. In the healthcare sector, cold spray has already proven effective in depositing a well-known biocompatible material—hydroxyapatite (HAP)—onto a wide variety of substrates without compromising HAP’s integrity. Architects, meanwhile, can leverage cold spray to create endlessly aesthetically pleasing metallic patterns on virtually any metal or ceramic substrate.
Nanotechnology and intelligent structures. Some non-traditional applications involve the use of advanced materials, such as nanostructured and amorphous materials. In nanostructured materials, the particle size is extremely small, enabling them to exhibit exceptional fracture toughness while maintaining high mechanical strength and other advantageous properties. Nanocrystalline materials are highly sensitive to processing temperature; therefore, cold spraying can be employed effectively without compromising their beneficial microstructure.
Due to its low deposition temperature, cold spraying enables the embedding of micro-sensors and their functional coatings onto surfaces, thereby creating intelligent structures. These structures can provide real-time information related to material properties or environmental conditions. Many emerging companies are focusing on delivering sensing, database management, and pre-analysis solutions for bridges, power grids, wind turbines, aircraft, automobiles, ships, pipelines, and construction equipment. The future of cold spraying hinges on achieving advanced material deposition onto a wide variety of substrates while minimizing heat loss and costs. This forms the cornerstone for defining the future direction and opportunities of this technology.
Materials - Equipment - Processes - Solutions
We have accumulated extensive experience in coating applications, and we are now replicating these successful case studies. We’ll guide you through the entire coating manufacturing transformation process, ensuring: rapid production start-up; a reliable supply solution that covers everything—from materials and equipment to processes; coating trials conducted either on-site at your facility or at our technology center; and consistently high coating quality and efficiency. Start collaborating with us today and reap success tomorrow!
Relevant Information
The complete set of plasma-sprayed equipment has been shipped to the customer’s site in Thailand.
Core spraying equipment: SX-80 plasma spray main unit, with a 15,000℃ flame suitable for multiple materials including zirconia and silicon carbide; powder feeding accuracy of ±1%, and coating thickness tolerance ≤ ±5 μm. Environmental protection support system: Customized soundproof booth + pulse dust collector—effectively addressing spray noise pollution while achieving highly efficient dust recovery, compliant with Thai environmental standards. Automated equipment: 6-axis industrial robot + intelligent spray cart, enabling precise spraying of complex workpieces and automated loading/unloading, boosting production efficiency by 40%.
On-site engineers provide hands-on training, focusing on the core operations of plasma spraying equipment such as the SX-80. Sanxin has customized a complete solution for its customers, including an automated spraying robotic arm, a soundproof booth, and a dust removal system—ensuring both high spraying efficiency and compliance with environmental standards.
Guangzhou Sanxin Thermal Spraying Turntable Shipment
Guangzhou Sanxin Company manufactures single-station and multi-station thermal spray turntables, which can be paired with plasma equipment, supersonic equipment, and arc equipment. We offer rapid, customized production tailored to customer requirements and product dimensions. A thermal spray turntable is a high-precision rotary worktable specifically designed for thermal spraying processes—including flame spraying, plasma spraying, and arc spraying. By providing controllable rotational speed and exceptional stability, it ensures uniform coating thickness on the workpiece surface, thereby enhancing spraying efficiency and quality.
SX-80 plasma equipment is being used at a customer site in Russia.
SX-80 plasma equipment is being used at a customer site in Russia.
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